Pasta process and products

ABSTRACT

Process of producing shelf stable dehydrated rehydratable pasta products having greater than usual moisture contents, by cooking said pasta products in a solution comprising polyhydric alcohols salts, and an antimycotic.

United States Patent Halik [151 3,655,401 1 Apr. 11, 1972 [541 PASTAPROCESS AND PRODUCTS [72] Inventor: Joseph John Halik, Ossining, N.Y.

[73] Assignee: General Foods Corporation, White Plains,

[22] Filed: J l 28,19 9

[ Appl.No.: 845,484

[52] U.S. Cl. ..99/85, 99/150 R Field of Search ..99/85, 150 R PrimaryExaminer-Raymond N. Jones Assistant Examiner.lames R. HoffmanAttomey-Thomas V. Sullivan, Bruno P. Struzzi and Jerome J. Norris [57]ABSTRACT Process of producing shelf stable dehydrated rehydratable pastaproducts having greater than usual moisture contents, by cooking saidpasta products in a solution comprising polyhydric alcohols salts, andan antimycotic.

6 Claims, No Drawings PASTA PROCESS AND PRODUCTS BACKGROUND OF THEINVENTION This invention relates to a new and improved process forcooking farinaceous materials. More particularly, the invention isconcerned with a new and improved process for heat treatment of pastaproducts under conditions which convert the product into an edible formwhile collaterally stabilizing said product against microorganicdecomposition.

Food products such as pasta products have heretofore been cooked,primarily in an excess of water, whereupon the food undergoes anenzymatic inactivation, and upon further heat treatment the product issoftened or otherwise further alteredphysically or chemically; suchalteration, in the case of starch containing foods is commonly termedgelatinization. Significantly, such cooking processes do not promote anymaterial changes in the microorganic stability of the foodstuff per se,and storage and packaging other than by commercial sterilization(canning) techniques cannot be utilized. However, in the case ofvegetables, commercial canning procedures may require prolonged heatingto kill spores of anaerobic bacteria and such prolonged heating canproduce undesirable loss of flavor and/or texture.

The primary object of the invention is to treat pasta products underconditions which produce partially dried intermediate moisture pastaproducts having a moisture content higher than currently marketedquick-cooking pasta products, and capable of rehydrating to a textureclose to that of cooked pasta products.

A further object of the invention is to treat pasta products underconditions which lend a more moist eating quality thereto, and yetessentially produces a product stable against microorganicdecomposition, such that the need for any further treatment to providebacteriostasis and protection against development of yeasts and/or moldsis avoided.

A yet further object of the invention is to produce a partially driedintermediate moisture pasta which is capable of rehydration upon soakingin excess cold or hot water for at least 5 minutes; after which theexcess water is poured off.

The term farinaceous refers to materials prepared from hard wheatflours, such as US No. l semolina, durum granular, and other floursmilled from amber and durum wheat, and blends thereof.

In general, the quickcooking dehydrated rehydratable pasta productspresently on the market will contain about 9 to 10 percent moisture,however, these products tend to be too dry and friable and requireconsiderable time to effect rehydration to produce the al dente" textureof conventionally cooked pasta products.

Briefly stated, the present invention eliminates the disadvantagesattendant to quick-cooking pasta products in current use, by preparing ashelf stable dehydrated rehydratable intermediate moisture pastaproduct. The concept of intermediate moisture food products is set forthin US. Pat. No. 3,202,514; these products usually have a moisturecontent in excess of 10 percent and substantially below 75 percent. Ingeneral, any significant elevation of the moisture level of many foodsabove 10 percent will increase their palatability, however, such anincrease tends to lead to microbiological decomposition unless the foodproducts are packaged in a hermetically sealed container andcommercially sterilized or maintained in a frozen or refrigerated statethroughout the period of distribution and storage by the consumer.

One method of preventing microbiological decomposition in foods havingmoisture in excess of 10 percent is by utilizing the principal oflimiting the amount of unbound water capable of supportingmicrobiological spoilage. This principle is disclosed in US. Pat. No.3,202,514, and is known as the Aw, or the ability of the soluble solidsin the food to limit the amount of free water available to bacteria; thebacteria's inability to survive this condition; and the subsequent shelfstability or product stability obtained by virtue of this condition.

Since shelf or product stability is the result of having sub stantiallytotally inhibited harmful mold as well as bacteriological growth, it hasbeen necessary to incorporate antimycotics such as potassium sorbate inintermediate moisture foods to prevent mold development and ultimateshelf instability.

SUMMARY OF THE INVENTION It has been found that shelf stable dehydratedrehydratable partially dried intermediate moisture pasta containingabout 35 to 40 percent moisture, may be prepared by parboiling the pastaproduct in boiling water; draining the excess water therefrom, andcooking the parboiled pasta product by immersing said product in anexcess boiling infusion solution comprising a polyhydric alcohol and anantimycotic.

Subsequent to said cooking step, the pasta product is cooled andrefrigerated in said solution; thereafter the solution is drained offand the cooked pasta products is permitted to surface dry to a highmoisture (35 to 40 percent), shelf stable form which is resistant tobacteriological and mold growth. The relative concentration ofpolyhydric alcohol utilized in p the boiling infusion solutionemployedin accordance with the invention will generally range upwardsfrom around 45 percent thereby enabling the amount of polyhydric alcoholin the final intermediate moisture pasta to be at least 25 percent. Inaddition to polyhydric alcohols, the boiling infusion solution willcontain other stabilizing solutes, which will include salts in amountsof about one-eighths percent by weight based on the polyhydric alcohol.Generally, the boiling infusion solution will contain glycerol as thepreferred polyhydric alcohol, and treatment of the parboiled pastaproduct in the infusion solution will be for a period of time sufficientto thermally deactivate any latent enzymatic and pathogenic activity.The stabilizing infusion solution of the invention is employed in anexcess amount to immersion cook the pasta and cause it to undergo awater substitution by the stabilizing solution, such that the polyhydricalcohols and salt will replace a part of the percent by weight of themoisture which has been absorbed in the parboiled pasta product. Therelative concentration of the polyhydric alcohols and salt used inaccordance with the invention will largely be determined by the flavorrequirement for the pasta product being so treated after removal of thewater during the rehydration step. Thus, if the percent of polyhydricalcohols in the shelf stable dehydrated rehydratable pasta product istoo high, a sweet taste will reside after the rehydration step of coldor hot soaking and pouring off the excess water. Similarly, taste andflavor considerations will also govern the upper feasible limits of saltpermissible in the final pasta product.

The infusion process of the invention essentially results indehydration, wherein a part of the moisture absorbed in the parboiledpasta product is partially substituted for by polyhydric alcohol andsalt solutes in sufficient concentration to substantially increase theosmotic pressure of the resulting solution infused into the final pastaproduct.

Treatment by the stabilizing infusing solution will preferably involveinitial cook wherein such solution will be elevated in temperature aboveF. and the parboiled pasta product immersed therein for at least 6minutes and preferably for a more prolonged period for about 8 minutes,until the degree of cooking or heat treatment produce the requiredsoftening or microorganic inactivation.

The rate of infusion will be determined by the concentration ofpolyhydric alcohols and salt solutes in the stabilizing solution, thehigher the concentrations of the solutes the greater the rate ofinfusion thereof, and accordingly the less the period required to effectsubstitution of water in the pasta product by polyhydric alcohols andsalt.

The process will find its broadest application with the treatment ofparboiled pasta products and contemplates treating said pasta to enablepackaging aerobically, i.e., packing under less than commercialsterilization conditions.

The expression polyhydric alcohol" refers to alcohols with two or morehydroxyl groups, most typically such alcohols as glycerol, propyleneglycol, sorbitol, mannitol, and mixtures thereof. However, theexpression contemplated in this invention" will also include a varietyof sugar alcohols which may be classed by the number of hydroxyl groupsand the general formula l-lOCH (Cl-10H) nCHCl-l, where n has values from2 to 5 like tetritols, penitols, hexitols, heptitols, etc., as well asstereoisomers thereof. In general these polyols are water-soluble,crystalline compounds with small optical rotations in water and have aslightly sweet to a very sweet taste. The polyhydric alcohols should beof a low molecular weight so as to offer a substantial effect inincreasing the osmotic pressure of the stabilizing solution contained inthe intermediate moisture pasta product.

It is a feature of the present invention that the cooking step utilizingthe stabilizing infusion solution is conducted in an excess of saidsolution, whereupon the weight level of solution to parboiled pastaproduct will range from 2:1 to :1 and above;

the stabilizing solution constituting a major percent by weight ofpolyhydric alcohols, and minor remaining percentages of water, salt, andan antimycotic. The principal objective is to effect dilution of themoisture which is absorbed into the pasta product during cooking,through partial substitution therefor by polyhydric alcohols and salt ina period of time commensurate with that degree of heat treatment orcooking required to produce the chemical and physical changes attendantto conventionally cooked pasta, and yet, following surface drying atambient temperature preparatory to rehydration for eventual eating, thedehydrated shelf stable pasta product will be higher in moisture contentthan quick-cooking pastas and will lack the dry friable qualities ofthese pastas.

Polyhydric alcohols used will be employed at a level in solution sothat, after completion of the infusion treatment and surface dryingstep, the dehydrated rehydratable intermediate moisture pasta productwill have at least 25 percent polyhydric alcohol; which to an extent isestablished by the level of salt solute in the cooking solution. As thelevel of salt in the cooking solution increases, the level of polyhydricalcohol that might otherwise be employed therein, will be reduced.

It has been found that in order to obtain a shelf stable dehydratedrehydratable pasta product of 35 to 40 percent moisture, which will notbe too sweet or salty upon rehydration, the amounts of polyhydricalcohol and salt contained in the stabilizing cook solution must be suchas to give rise to a rehydratable pasta product having at least 25percent polyhydric alcohol and at least 3 percent salt solubles. Thecorresponding cook solution necessary for production of proper tastingshelf stable rehydratable pasta will usually contain little more than atleast 45 percent of polyhydric alcohol, and at least 6 percent salt.

The preferred way to treat the pasta products intended for the cookinfusion solution is to parboil the dry pasta in water at temperaturesin excess of 160 F. for at least 6 minutes, to a moisture content of 5865 percent; draining the pasta and then subjecting the parboiled productto excess stabilizing cook solution above l60 F. for a time rangingbetween 6 to 8 minutes, so that any latent enzyme activity ormicroorganic instability precursors will be inactivated. Since the levelof additives in the infusion is high, adequate hydration of the starchin the pasta is achieved as a result of this infusion process. Aftercooking and draining, the pasta product is permitted to surface dry atambient temperatures for about 2 minutes to provide a product havingwater activity ranging from about 0.80 to 0.85.

Pasta products stabilized by the present invention will generally be ofat least two types. The first type will be products intended forconsumption after rehydrating in hot water to enhance the acceptabilityof the product in terms of flavor and texture. The second type of pastaproducts are those which are intended to be mixed with vegetables, suchas onions, green peppers and olive pieces after rehydration in excesscold water, to form salads.

Preferred salts which may be used in the invention will be readilyionizable low molecular weight compounds which increase the osmoticpressure of the stabilizing infusion solution, such that the solutionhas a significant increase in ability to provide bacten'ostasis andmicroorganic stability. Typical salts of use in accordance with theinvention are: sodium chloride, calcium chloride, sodium phosphate,trisodium citrate and like inorganic and organic acid salts commonlyused in foodstuffs, and mixtures thereof. Other salts of highermolecular weight which are less readily ionizable may be employed,however, with generally lesser effect in so far as bacteriostasis andmicroorganic stability are concerned.

The following examples will more specifically set forth the preferredembodiment of the invention:

EXAMPLE i Two hundred parts of macaroni solids is parboiled* (*It is tobe understood that the term parboiled means partially cooking in thisinvention.) in excess boiling water and simmered for about 8 minutes anddrained. The resulting moisture in the macaroni product was about 58percent. The parboiled product is immersed in 400 parts of boilinginfusion solution and boiled at about 212 F for about 8 minutes. Next,the macaroni is cooled and refrigerated in the immersion solution andpermitted to surface dry on absorbent paper for about 2 minutessubsequent to draining-off the solution to obtain a partially driedshelf stable intermediate moisture macaroni product having a moisturecontent ranging from about 35 to 40 percent and water activity rangingfrom 0.80 to 0.85. Upon equilibrating for approximately one day, thefinal product followed.

Ingredients Solutior|(%) Final Producttq Macaroni Solids 28.0 Water 35837.0 Sodium Chloride 6.6 3.6 Glycerol 53.4 29.2 Propylene Glycol 3.6 1.9Potassium Sorbate 0.6 0.3

Totals: i000 100.0

Actual percent moistures varied from 35 to 40 percent, water activitiesranged from 0.80 to 0.85 indicating microbiological stability at roomcondition storage without aseptic packaging.

Bacteriological results conducted on a portion of the sample afterstorage are shown below:

Sample Aw SPC Molds Yeast Zero time 0.85 10 10 3 weeks at l00F 0.85 1010 10 Standard Plate Count EXAMPLE ll Two hundred parts of spaghettisolids is parboiled in excess boiling water and simmered for about 8minutes and drained. The resulting moisture in the spaghetti product wasabout 60 percent. The parboiled product is immersed in 400 parts ofboiling infusion solution and boiled at about 212 F. for about 6minutes. Next, the spaghetti is cooled and refrigerated in the immersionsolution and permitted to surface dry on absorbent paper for about 2minutes subsequent to draining-off the solution to obtain a partiallydried shelf stable intermediate moisture spaghetti product having amoisture content ranging from about 35 to 40 percent and water activityranging from 0.80 to 0.85. Upon equilibrating for approximately one day,the final product followed.

Ingredients Solution(%) Final Product(l) Spaghetti Solids 24.6 Water42.1 38.8 Sodium Chloride 6.0 3.8 Glycerol 48.2 30.5 Propylene Glycol3.2 2.0 Potassium Sorbate 0.5 0.3

Totals: 100.0 100.0

Bacteriological results conducted on a portion of the sample afterstorage are shown below:

Sample Aw SPC Molds Yeast Zero Time 0.83 10 10 3 Weeks at 100F 0.83 1010 10 Standard Plate Count These results indicate that products up to anAw of 0.85 are still microbiologically stable.

The shelf stable rehydratable dehydrated spaghetti was rehydrated bysoaking in excess water at temperatures in excess of 160 F. for at least5 minutes and the excess water was poured-off to provide a good tastingspaghetti product having an appearance much like that of conventionallycooked spaghetti.

EXAMPLE Ill Two hundred parts of noodle solids is parboiled in excessboiling water and simmered for about 3 minutes and drained. Theresulting moisture in the noodle product was about 60 percent. Theparboiled product is immersed in 400 parts of boiling infusion solutionand boiled at about 212 F. for about 6 minutes. Next, the noodles arecooled and refrigerated in the immersion solution for 4 hours andpermitted to surface dry on absorbent paper for about 2 minutessubsequent to draining-off the solution to obtain a partially driedshelf stable intermediate moisture noodle product having a moisturecontent ranging from about 35 to 40 percent and water activity rangingfrom 0.80 to 0.85. Upon equilibrating for approximately one day, thefinal product followed.

lngredients Solution(%) Final Product(%) Noodle Solids 30.4 Water 41.038.0 Sodium Chloride 6.1 3.3 Glycerol 49.0 26.2 Propylene Glycol 9.6 1.8Potassium SorbGtB Totals: 100.0 100.0

The shelf stable rehydratable dehydrated noodles were rehydrated bysoaking in excess water at temperatures in excess of 160 F. for at least5 minutes and the excess water was poured-off to provide a good tastingnoodle product having an appearance much like that of conventionallycooked noodles.

While a specific formulation and procedure have been given for thepreparation of partially dried intermediate moisture pasta, it can beseen that variations in formulas and procedures as well as startingmaterials are possible. For example, the cooking time will vary with thetype of pasta used. Optimum cooking time will be that which thoroughlycooks the particular pasta without cooking.

The concentrations of the ingredients in the infusion solution willdepend mainly on the final moisture in the product and also to someextent on the final Aw desired as well as the level of antimycotics.

It has been found that rapid bacteriological spoilage will take place atAw's above 0.88. Below that level, growth is generally inhibited, butthere may be occasional organisms that will grow at Aws below 0.88.Whether there are such organisms in pasta and whether they will grow inpasta would have to be determined. In general, Aws in the range of 0.80to 0.85 are safe based on the tests conducted.

Another important factor for microbiological stability, especially moldand yeast inhibition, is the type and amounts of antimycotics used inthe pasta. The formula given uses about 2.0 percent propylene glycol andabout 0.3 percent potassium sorbate as the antimycotic system. Theselevels ave been found to be effective in the intermediate moisture pastaproducts. However, lower levels would also be effective.

What is claimed is:

l. A process for producing shelf stable dehydrated rehydratable pastaproducts having a moisture content between about 35 to 40 percent,comprising parboiling the pasta in excess boiling water for at least 3minutes, draining off said excess water, immersion cooking the pastaabove F. in a stabilizing solution for a period sufiicient to thermallyinactivate enzymatic and pathogenic activity of the pasta, cooling thesolution, and surface drying the pasta; said stabilizing solutioncontaining in excess of about 45 percent polyhydric alcohol, at least 6percent salt, and sufficient antimycotic to prevent mold growth.

2. The process of claim 1 wherein the parboiled pasta is immersioncooked in the solution at a temperature in excess of 160 F. for a periodin excess of 5 minutes.

3. The process of claim 1 wherein the salt present in the solution isselected from the class of readily ionizable salts.

4. The process of claim 1 wherein the pasta treated is macaroni.

5. The process of claim 1 wherein the stabilizing solution is removedfrom the cooked pasta product subsequent to cooling and permitted tosurface dry on absorbent paper for about 2 minutes.

6. The shelf stable dehydrated rehydratable pasta product produced bythe process of claim 1.

Patent No. 3,655,401 Dated A p-11, 1972 Inventor( s) Joseph John HalikIt is certified that error appears in the above-identified patent andthat said Letters Patent are hereby corrected as shown below:

Title page, in the-ABSTRACT, Line 4 after "alcohols" and before "salts"insert In Column 5, starting at Line 40 change the table to read:

Ingredients Solution Final Product Noodle Solids 30.4 Water 41.0 38.0Sodium Chloride 6.1 3.3 Glycerol 49.0 26.2 Propylene Glycol 3.4 1.8Potassium Sorbate 0.5 0.3

Totals 100. 0 100.0

Signed and sealed this 24th day oi April 1973.

(SEAL) Attest:

EDWARD M. FLETCHER, J'B. ROBERT GOTTSCHALK Attesting OfficerCommissioner of Patents ORM PO-105O (1M9) USCOMM-OC 60376-P69 a as.GOVIIINMINT 7 mm us omcl an o-au-au

2. The process of claim 1 wherein the parboiled pasta is immersioncooked in the solution at a temperature in excess of 160* F. for aperiod in excess of 5 minutes.
 3. The process of claim 1 wherein thesalt present in the solution is selected from the class of readilyionizable salts.
 4. The process of claim 1 wherein the pasta treated ismacaroni.
 5. The process of claim 1 wherein the stabilizing solution isremoved from the cooked pasta product subsequent to cooling andpermitted to surface dry on absorbent paper for about 2 minutes.
 6. Theshelf stable dehydrated rehydratable pasta product produced by theprocess of claim 1.